Reinforced structure apparatus

ABSTRACT

An apparatus for manufacturing reinforced structures wherein a hardened steel shell is constructed to desired specifications and anchored to a structure&#39;s foundation. The remainder of the structure is constructed around the hardened steel shell, thereby incorporating the steel shell as an integrated room or section of the structure.

CROSS REFERENCES TO RELATED APPLICATIONS

THIS APPLICATION IS A CONTINUATION OF NON-PROVISIONAL PATENT APPLICATIONSER. NO. 10/967,878, FILED OCT. 18, 2004, CURRENTLY PENDING.

STATEMENTS AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSOREDRESEARCH AND DEVELOPMENT

NONE

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a reinforced structure. Moreparticularly, the present invention relates to an apparatus formanufacturing reinforced components of dwellings and other buildings.More particularly still, the present invention relates to an apparatusfor reinforcing rooms and/or areas of dwellings and other buildingscapable of withstanding hurricanes, tornadoes, earthquakes and otherthreats.

2. Description of the Prior Art

Generally, walls of dwellings and other similar buildings are made fromwood, bricks and/or hollow masonry blocks, while roofs are made fromwood. Frequently, wooden trusses, especially nailed trusses, span theentire interior of such buildings. Although such buildings can be veryeconomical to construct, they generally cannot withstand the effects ofa hurricane, tornado, earthquake or other disaster. In many instances,such structures can be severely damaged, if not completely destroyed, bysuch a disaster. Further, buildings in general, and houses inparticular, are typically not of fire resistant construction and aresusceptible to considerable damage due to fires.

In addition to threats from fires and natural disasters, buildingsand/or dwellings constructed using conventional methods are alsovulnerable to “man-made” threats. Such man-made threats can includeforced entry by intruder(s), as well as chemical, biological or nuclearattacks.

Numerous attempts have been made to protect against such threats. Theconcept of safe rooms, “panic rooms” and/or fallout structures withinbuildings and other dwellings is previously known. Generally, prior artsafe rooms and the like comprise separate rooms or attachments tobuildings or other dwellings which are made of fire, blast and/orbreak-in resistant construction. However, such safe rooms generally arenot an integral part of a building itself, adding to its structuralstrength and integrity. Further, such specialized rooms or shelters arerarely, if ever, used unless a specific need arises.

In many areas, dwellings and other buildings can be constructed withstorm shelters and/or fallout'shelters in cellars or other undergroundlocations. However, in certain geographic regions, such as in thevicinity of the Gulf of Mexico, buildings (including residentialdwellings)-are often constructed without cellars because the groundwater level is too high. As such, buildings in these areas typicallyhave only a concrete slab for a foundation, and safe rooms, “panicrooms” and/or fallout shelters cannot be constructed in cellars.

Thus, the need exists for a reinforced room or section of a building ordwelling which can withstand high winds associated with tornadoes and/orhurricanes, as well as blasts from other sources. Similarly, suchreinforced room or section should be fire resistant, and should be ableto withstand negative effects of earthquakes. Such reinforced room orsection should be an integral part of said building or dwelling, andshould be able to be capable of being used and enjoyed even when notbeing utilized as a disaster shelter.

SUMMARY OF THE INVENTION

As opposed to specialized fallout or storm shelters that are rarely ifever used, a building incorporating the apparatus for the presentinvention integrates the security benefits of such fallout shelters,storm shelters and/or so-called “panic rooms” into fully functionalroom(s) in such building. Buildings incorporating the apparatus of thepresent invention offer full functionality, even when the reinforcedrooms and/or sections of such buildings are not being specifically usedas a shelter. Dwellings and other buildings incorporating the apparatusfor the present invention are engineered to withstand tornadoes,hurricanes, forced entry by intruders and automobile intrusion, fire,ballistic damage, chemical or toxic releases, and tidal/storm surges.

Buildings incorporating the apparatus of the present invention can bedesigned into virtually any new construction project, or can be addedinto virtually any existing building or dwelling. Alternatively, theapparatus for the present invention can be used in the construction ofstand-alone structures.

In the case of slab foundation buildings, a proprietary anchor system isinstalled within such slab. Once the slab is poured, steel room (orgroup of rooms) is constructed, typically at an off-site location.Thereafter, such room(s) are delivered to the construction site, set inplace and mechanically fastened to such slab using anchoring devices.

Room(s) incorporating the apparatus of the present invention areequipped with their own electrical, HVAC, plumbing rough-ins and sheetrock walls/ceilings. In the preferred embodiment, such room(s) aredesigned to be totally self-contained, and are tied to a generator(typically powered by natural gas) that will automatically actuate whenthe building's standard source of power is lost.

The building or other dwelling is then manufactured around the roomincorporating the apparatus for the present invention. Roof joists canbe affixed to the steel room or wing, making such room immenselystronger and capable of withstanding higher wind loads, fire, ballisticforces and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an exploded perspective view of a steel structure of thepresent invention.

FIG. 2 depicts a perspective view of a steel structure of the presentinvention being delivered to a construction site.

FIG. 3 depicts a perspective view of a steel structure of the presentinvention being installed at a construction site.

FIG. 4 depicts a cross-sectional side view of a slab foundation for adwelling or other building.

FIG. 5 depicts a cross-sectional cut-away view of a dwelling constructedusing the apparatus of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring to the drawings, FIG. 1 depicts an exploded perspective viewof a shell having an internal space formed by steel structure 1 of thepresent invention. Steel structure 1 can be fabricated in any number ofdifferent configurations. In the preferred embodiment, steel structure 1is designed to fit the design parameters of a dwelling or other buildinginto which such steel structure 1 is to be incorporated.

Although steel structure 1 can be configured any number of differentways, in the preferred embodiment of the present invention, said steelstructure 1 has substantially horizontal planar floor 2, a plurality ofside walls 3 and substantially horizontal planar ceiling 4. Saidsubstantially horizontal planar floor 2, side walls 3 and substantiallyhorizontal planar ceiling 4 together form an enclosure defining interiorspace within steel structure 1. It is to be observed that substantiallyhorizontal planar ceiling 4 is anchored to the upper portion of sidewalls 3; however, said horizontal planar ceiling 4 is shown in explodedFIG. 1 to illustrate the interior space within steel structure 1.

In the preferred embodiment, steel structure 1 is initially fabricatedfrom a tubular steel frame. Thereafter, steel plates having desiredstrength characteristics are welded to said frame in order to formsubstantially horizontal planar floor 2, vertical side walls 3 andsubstantially horizontal planar ceiling 4. Of course, while thepreferred embodiment of the present invention describes use of steel,other materials such as composites having desired characteristics couldbe employed in place of steel in certain applications.

Still referring to FIG. 1, external doorway 5 is provided in at leastone vertical side wall 3. Depending upon the configuration of steelstructure 1, it may be desirable to incorporate more than one doorwayinto the design of steel structure 1, but this will typically depend onthe desired layout of said steel structure 1. Doorway 5 permits accessto the internal space of steel structure 1 defined by substantiallyplanar floor 2, vertical side walls 3 and substantially horizontalplanar ceiling 4. Similarly, optional window openings 6 can befabricated into vertical side walls 3.

At least one optional internal wall 7 having internal doorway 3 can beconstructed within the interior space of steel structure 1. Althoughsuch internal wall(s) are not required, said walls may be desirable todivide or configure the internal space within steel structure 1. By wayof example, but not limitation, when steel structure 1 of the presentinvention is utilized as the master suite of a dwelling, it is typicallydesirable to incorporate one or more internal walls to define a masterbath area, closet space and the like. Although such internal walls canbe constructed of steel or other reinforcing material, in mostapplications this is not necessary because vertical side walls 3 ofsteel structure 1 provide desired strength characteristics for theentire internal space defined within steel structure.

In the preferred embodiment, reinforced case 9 is provided. Althoughreinforced case 9 can be situated in any number of different locations,in most applications said reinforced case is located on the uppersurface of substantially planar horizontal ceiling 4. Said reinforcedcase 9 can be used to house hot water heater(s), HVAC equipment and/orother life support components.

FIG. 2 depicts a perspective view of steel structure 1 of the presentinvention being delivered to an installation site. Although it ispossible that such steel structure 1 can be manufactured at suchinstallation site, in the preferred embodiment said steel structures ismanufactured at another site, such as a remote fabrication facility, andthen transported to an installation site via truck 20.

Referring to FIG. 3, steel structure 1 is off-loaded from truck 20 usingcrane 21. Said steel structure 1 is positioned on to building foundationslab 30 using crane 21. Specifically, steel structure 1 is positioned ona predetermined portion of building foundation slab 30 which has beendesigned to receive said steel structure 1. In the preferred embodiment,said building foundation slab 30 includes a plurality of anchor bolts 31which are implanted or otherwise installed within said slab 30 andprotrude vertically upward out of building foundation slab 30.Similarly, plumbing/utility stubs32 extend upward from said buildingfoundation slab 30.

FIG. 4 depicts a detailed cross-sectional view of building foundationslab 30. Said building foundation slab 30 has footers 33 which extendinto ground 34. Said building foundation slab has upper surface 35 andrecessed area 36 partially defined by upper surface 36 a. Recessed area36 is sized and configured to receive steel structure 1, which restsupon recessed upper surface 36 a of building foundation slab 30. Anchorbolts 31 and plumbing/utility stubs32 extend upward from buildingfoundation slab 30 within recessed area 36. Said anchor bolts 31 andplumbing/utility stubs 32 are spaced to be received within matingapertures within substantially horizontal planar floor 2 of steelstructure 1.

FIG. 5 depicts a cross-sectional view of a reinforced room constructedin accordance with the present invention within standard dwelling 50.Steel structure 1 of the present invention is incorporated within suchdwelling 50. Steel structure 1 can be fabricated in any number ofdifferent configurations and typically comprises substantiallyhorizontal planar floor 2, plurality of vertical side walls 3 andsubstantially horizontal planar ceiling 4. In the preferred embodiment,steel structure 1 is configured to fit the design parameters of dwelling50. In many cases, the steel structure 1 will comprise and be coincidentwith the master suite of dwelling 50, but it is to be observed that saidsteel structure can be incorporated into in any number or other areaswithin dwelling 50.

Building foundation slab 30 has footers 33 which extend into ground 34.Said building foundation slab has upper surface 35 and recessed area 36partially defined by upper surface 36 a. Recessed area 36 is sized andconfigured to receive steel structure 1, which rests upon recessed uppersurface 36 a of building foundation slab 30. Anchor bolts 31 extendupward from building foundation slab 30 within recessed area 36. Saidanchor bolts 31 are spaced to be received within mating apertures withinsubstantially horizontal planar floor 2 of steel structure 1. Steelstructure 1 is mechanically anchored to building foundation slab 30using anchor bolts 31. Although not shown in FIG. 5, plumbing and/orutility fixtures (such as plumbing/utility stubs 32 in FIG. 4) are usedto bring plumbing and/or electricity into the area(s) within steelstructure 1.

Still referring to FIG. 5, external doorway 5 is provided in at leastone vertical side wall 3 of steel structure 1. In FIG. 5, although saiddoorway 5 is situated along an external wall of steel structure 1, saiddoorway is located internally within dwelling 50. Depending upon theconfiguration of steel structure 1, it may be desirable to incorporatemore than one such doorway into the design of steel structure 1, butthis will typically depend on the desired layout of said steel structure1 and dwelling 50. Doorway 5 permits access to the internal space ofsteel structure 1 defined by substantially planar floor 2, vertical sidewalls 3 and substantially horizontal planar ceiling 4 from other areasof dwelling 50. Reinforced, heat resistant door 51 is mounted withindoorway 5. Similarly, windows manufactured from blast resistant glass orother similar material(s) can be installed within the window openings 6in side walls 3 of steel structure 1.

At least one optional internal wall having an internal doorway can beconstructed within the interior space of steel structure 1. Althoughsuch internal wall(s) are not required, said walls may be desirable todivide or configure the internal space within steel structure 1. By wayof example, but not limitation, when steel structure 1 of the presentinvention is utilized as the master suite of a dwelling, it is typicallydesirable to incorporate one or more internal walls to define a masterbath area, closet space and the like. Although such internal walls canbe constructed of steel or other reinforcing material, in mostapplications this is not necessary because vertical side walls 3 ofsteel structure 1 provide desired strength characteristics for theentire internal space defined within steel structure 1.

Reinforced case 9 is provided on the upper surface of substantiallyplanar horizontal ceiling 4 of steel structure 1. Said reinforced case 9can be used to house generator 52, HVAC equipment 53 and/or other lifesupport components, such as a hot water heater. Gas line 54 suppliesfuel to generator 52.

After said steel structure 1 is installed on building foundation slab30, other portions of dwelling 50 can be constructed. For example,joists 55 and truss members 56 can be used to support roof 57. Wheredesired, external surfaces of dwelling 50 can be equipped with desiredfinishes, such as brick surfaces 58. Internal surfaces of steelstructure can be equipped with sheet rock 59 and flooring 60. In thepreferred embodiment, steel structure 1 blends seamlessly into dwelling50 and is not visible from the outside or inside living area of dwelling50.

In certain applications, a room or other section of building installedin accordance with the present invention can include a positive pressuresystem. Such positive pressure system prevents chemical, biological orother agents from entering the living space defined by steel structure1.

Whereas the invention is herein described with respect to a preferredembodiment, it should be realized that various changes may be madewithout departing from essential contributions to the art made by theteachings hereof.

1. A reinforced structure comprising: a) a foundation; b) a building,having a plurality of rooms, attached to said foundation; and c) a steelshell structure having an internal space and at least one openingextending into said internal space, wherein said steel shell structureis anchored to said foundation and is substantially coincident with atleast one room of said building.
 2. The reinforced structure of claim 1,wherein said steel shell structure comprises a tubular steel frame. 3.The reinforced structure of claim 2, wherein said steel shell structurefurther comprises a plurality of steel plates attached to said tubularsteel frame.
 4. The reinforced structure of claim 1, further comprisingat least one wall covering material on at least one internal surface ofsaid steel shell structure.
 5. The reinforced structure of claim 4,wherein said at least one wall covering material comprises sheet rock.6. The reinforced structure of claim 1, further comprising at least onefinish material to at least one external surface of said steel shellstructure.
 7. The reinforced structure of claim 6, wherein said at leastone finish material is brick.
 8. A reinforced structure comprising: a) afoundation; b) a building, having a plurality of rooms, attached to saidfoundation; c) a steel shell structure having an internal space and atleast one opening extending into said internal space, wherein said steelshell structure is anchored to said foundation and is substantiallycoincident with at least one room of said building; and d) an electricalgenerator wired to at least one electrical outlet disposed in said steelshell structure.
 9. The reinforced structure of claim 9, wherein saidelectrical generator is disposed within a steel case attached to saidsteel shell structure.
 10. The reinforced structure of claim 8, whereinsaid electrical generator is fueled by natural gas.
 11. The reinforcedstructure of claim 8, wherein said steel shell structure comprises atubular steel frame.
 12. The. reinforced structure of claim 9, whereinsaid steel shell structure further comprises a plurality of steel platesattached to said tubular steel frame.
 13. The reinforced structure ofclaim 8, further comprising at least one wall covering material on atleast one internal surface of said steel shell structure.
 14. Thereinforced structure of claim 11, wherein said at least one wallcovering material is sheet rock.
 15. The reinforced structure of claim8, further comprising at least one finish material to at least oneexternal surface of said steel shell structure.
 16. The reinforcedstructure of claim 13, wherein said at least one finish material isbrick.
 17. The reinforced structure of claim 8, wherein said steel shellstructure further comprises at least one window opening.
 18. Thereinforced structure of claim 17, further comprising at least one windowhaving blast resistant glass in said at least one window opening. 19.The reinforced structure of claim 8, wherein said steel shell structurefurther comprises at least one doorway opening.
 20. The reinforcedstructure of claim 17, further comprising at least one reinforced doorin said at least one at least one doorway opening.